This document is a project report on a pneumatic shaper machine. It contains an abstract, table of contents, and begins discussing pneumatic systems and their advantages like high effectiveness, durability, safety, and cost-effectiveness. It describes how pneumatic power will be used in this shaper machine instead of a crank and link mechanism to provide reciprocating motion. The report will continue analyzing components of pneumatic systems like compressors, cylinders, and control valves. It will also discuss the applications and limitations of pneumatic actuation.

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A Project Report
On
PNEUMATIC SHAPER MACHINE
Submitted by
Patel Rahul (126540319546)
Rathod Chirag (126540319541)
Patel Achal (126540319548)
Draji Parag (126540319561)
Guided By
Mr. Nilesh Kadiya
Lecturer, Mechanical Engineering Department
A REPORT SUBMITTED TO
GUJRAT TECHNOLOGICAL UNIVERCITY
IN PARTIAL FULFILLMENT OF THE REQUIREMENT
FOR THE SUCCESSFULLY COMPLED OF PROJECT WORK
FOR 5TH SEM DIPLOMA MECHANICAL ENGG
VPMP POLYTECHNIC
Gandhinagar
2014-2015

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VPMP POLYTECHNIC
MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that work embodied in this report entitled “PNEUMATIC SHAPER
MACHINE” was carried out by 1. Patel rahul (126540319546), 2.rathod chirag
(126540319541),3. Patel achal (126540319548),4. Daraji parag (126540319561) at
V.P.M.P POLYTECHNIC for partial fulfillment of DIPLOMA MECHANICAL
ENGINEERING to be awarded by GUJARAT TECHNOLOGICAL UNIVERSITY.
This work has been carried out under by supervision and is to my specification.
Guided By: H.O.D.
Mr. Nilesh kadiya Mr. K.K. Mehta
External Examiner

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ACKNOWLEDGEMENT
I am profoundly grateful to PROF N.S.KADIYA for his expert guidance and
continuous encouragement throughout to see that this project rights its target since its
commencement to its completion.
I would like to express deepest appreciation towards MR.A.J.PAETL, Principal
V.P.M.P POLYTECHNIC and MR K.K.MEHTA., HOD Mechanical Branch whose
invaluable guidance supported me in completing this project.
At last I must express my sincere heartfelt gratitude to all the staff members of
Mechanical Branch who helped me directly or indirectly during this course of work.
Patel Rahul (126540319546)
Rathod chirag (126540319541)
Patel achal (126540319548)
Draji parag (126540319561)

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INDEX
CHAPTER DETAIL PAGE NO.
1 Introduction
2 Literature Review
3 Developmentif Pneumatic shaper machine
3.1 Pneumatic systems
3.2 The advantages of pneumatic systems
3.2.1 High effectiveness
3.2.2 High durability and reliability
3.2.3 Simple design
3.2.4 High adaptability to harsh environment
3.2.5 Safety
3.2.6 Easy selection of speed and pressure
3.2.7 Environmental friendly
3.2.8 Economical
3.3 Limitations of pneumatic systems
3.3.1 Relatively low accuracy
3.3.2 Low loading
3.3.3 Processing required before use
3.3.4 Uneven moving speed
3.3.5 Noise
3.4 Main pneumatic components
3.4.1 Compressor
3.4.2 Pressure regulating component
3.4.3 The consumption of compressed air
3.4.4 Execution component

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3.4.5 Single acting cylinder
3.5 Control valve
3.5.1 Non-return valve
3.5.2 Flow control valve
3.5.3 Shuttle valve
3.6 Application
3.7 Characteristic:
3.8 Disadvantages for Pneumatics
4 CostEstimation
4.1 Introduction:-
4.2 Purpose of Cost Estimating
4.3 Types of Cost Estimation
4.3.1 Material Cost Estimation
4.3.2 Material for fabrication
4.3.3 Standard purchased parts
4.4 Mavhining Cost Estimation
5 Conclusionand Future Scope
5.1 Future Scope
5.2 Conclusion
6 Reference

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ABSTRACT
A pneumatic can be thought of a large flexible mechanical structure that is moved by
some sort of control system. The control system takes its input from human operator
& translates this command into the motion of actuators, which move the mechanical
structure. The high performance and highly powerful.
Pneumatic operated pneumatic shaper machine is efficient machine which
works by pneumatic power, inserted of crank & shaping link mechanism here
pneumatic power is employed with quick return mechanism this system consist of
ram, pneumatic cylinder, time circuit when air from compressor is send to double
acting cylinder via solenoid valve, this valve will make the cylinder to move too & for
as per the single from the timer. Time will be programmed with delay.

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1. Introduction
A pneumatic system is a that uses compressed air to transmit & control energy.
pneumatic system are used in automatic production lines ,mechanical clamps.
Slotting machine can be considered as vertical shaping machine where the single
point reciprocates vertically (without quick return effect )and the work piece , being
mounted on the table , is given slow longitudinal and or rotary feed as can be seen in
fig 1 .slotting machine are generally used to machine internal surface
It is generally used ,instead of general production ,for their piece production required
for repair & maintenance.
Where instead of single point tool a large number of size & high speed milling cutters
are used…..
Pneumatic actuation systems are widely used in robotics and automation
applications due to their multiple advantages, e.g. low cost, high power-weight ratio,
cleanness, etc. However, the compressibility of the working fluid and the highly
nonlinear nature of the pneumatic systems pose great difficulty in their control. As
such,
initial application of pneumatic actuation systems was limited to the simple
positioning tasks realized with simple on-off control valves and mechanical stops.
The aforementioned works require the use of expensive control valves, and the cost of
valves dominates the cost of actuator in almost all cases. This inspires the research in
the first topic of this dissertation. Pulse width modulated (PWM) control offers the
ability to provide servo control of pneumatic actuators at a significantly lower cost by
utilizing binary solenoid valves in place of proportional servo valves. Instead of
continuously varying the resistance of the control valve as in the case of proportional-
valve-based systems, PWM-controlled systems meter the power delivered to the
actuator discretely by delivering packets or quanta of fluid mass via a valve that is
either completely on or completely off. If delivery of these packets of mass occur on a
time scale that is significantly faster than the system dynamics (i.e., dynamics of the
actuator and load), then the system will respond in essence to the average mass flow
rate into and out of the cylinder, in a manner similar to the continuous case
Despite the prior work on the control of pneumatic servo systems, little work has
focused on exploiting the unique characteristics of the pneumatic systems. Different
from that of an electromagnetic motor, the behavior of a pneumatic actuator is
essentially a series elastic actuator, in which the compressed air acts as the elastic
element. Thus, the stiffness of this elastic actuator physically exists and can be
modulated by controlling the air masses in the actuator chambers. The research in the
second and third topic of this dissertation leverages this unique characteristic to
simultaneously control the output force and stiffness of a robotic actuator, and
enhance the passivity of haptic interfaces, respectively.

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Energy efficiency in the control of pneumatic servo systems is another topic that has
received little attention before, partly because the compressed air supply in most cases
is unlimited, e.g. from a power plant. With the increasing applications of pneumatic
actuation in robotics, especially those in mobile robots, energy efficiency is becoming
a more significant issue. As previously mentioned, the behavior of a pneumatic
actuator is essentially a series elastic actuator, in which energy can be stored in the
elastic element compressed air in the actuator chambers. If the energy stored in the
compressed air can be reused rather than dissipated by exhausting to the atmosphere,
a large portion of energy can be saved. This inspires the research in the fourth topic of
this research, which achieves energy-saving control of pneumatic servo systems by
utilizing cross-chamber flow

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Figure 1 Base Diagram
Table 1 part name
Part No Part Name Qty
1 Pieces 1
2 Cutting Tool 1
3 Tool holder 1
4 Ram 1
5 Operating cylinder 1
6 Piston 1
7 Pipe 4

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1.1 Definition of project
In this project we define the quick return effect replace by pneumatic pressure.
2 LITERATURE REVIEW
ClassificationThere are mainly two types of shapers :-
TYPES OF SHAPER MACHINE
1. According to the type of mechanisam used for giving reciprocating
motion of the ram
(a) Crank type
In these shapersthe reciprocatingramisdrivenbycrankmechanism.Inthisa single point
cuttingtool is employedtodothe operation.A crank isconnectedtothe ram and the bull
gear to whichthe powerisgiventhroughanindividualmotor.These are mostcommontype
of shapersbeingused.The reciprocatinglengthof tool willbe alwaysisequal tothe length
of stroke.

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(b) Geared type
These are the rarelyusedshapers.Inthese shapersarack and pinionare employed
the rack isattachedto the lowerpart of the ram andon whichthe pinionmoves.The power
istransmittedfromthe bull gear.A grain trainis engagedforthe transferof powerfromthe
bull gearto pinion.
(c) Hydraulic type

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These shapersrunon hydraulicpower.The endof the ram isconnectedtoa pistonfittedin
to a cylinder.Oil isfedintothe cylinderinitiallythe oil acts inone directionandthe ram
movesinone direction.A varyingpressure isappliedonthe oil soas to obtainthe
reciprocatingmotionof the ram.One of the mainadvantage of thisshaperis a constant
speedcanbe obtainedfromthe startingof the machiningoperation.Therewillbe no
fluctuationsinthe cuttingspeedandstroke of the ram.Anotherimportantadvantage of this
shaperisno soundwill be producedhence anoise free environmentcanbe obtained.
2. According to the position and travel of ram
(a) Horizontal type
As the name indicatesthese shapershave the motionof ramalongthe horizontal axis.Thistype of
shapersisgenerallyusedforgenerationof fine andflatsurfaces.

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(d) Vertical type
In these shapersthe tool containingramhasitsmotioninvertical direction.Insome of the
shapersa provisionof 100 rotationof the ram is alsoprovided.Invertical shaperthe ram
may be drivenbyvarioustypeslike crankdriven,screw driven,geardriven,orbyhydraulic
power.Vertical shapingmachinesfindsmanyapplicationsindeephole boring,machining
internal surfaces,keyways,groovesetc.vertical shaperhasa veryrobusttable whichcan
have cross, longitudinal,androtational movement.The tool usedona vertical shaperis
totallydifferentfromthatof the normal tool whichisemployedonahorizontal shaper.
(c) Traverling head type

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Thistype of shaperisgenerallyemployedformachiningverylarge objectsthatcannotbe
mountedonthe table of the machine andcannotbe moved.Inthismachine the ramhaving
reciprocatingmovementalsoprovidescrosswise movementsimultaneouslysuchthatthe tool
can cut the requiredshape onthe workpiece.
3. Accroding to the type of design of the table:-
(a) standard shaper
In these shaperthe table hasonlytwomovementsi.e.vertical andhorizontal.The table
may or may notbe supportedonthe otherend.These are notgenerallyused

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(b) Universal shaper
In these shapersinadditiontothe above mentionedtwomovementsof the standard
shaperit providestwomore directions.
1) By swellingthe table aboutaaxisram ways.
2) The table can be tiltedaboutanaxisperpendiculartothe 1 st one
So due to these twofeaturesanyoperationatanyangle can be performedveryeasily.So
due to these featuresthe shaperistermedasa universal shaper
3. Introductionof pneumatic system (Development if Pneumatic
shaper machine)
3.1 Pneumatic systems
A pneumatic system is a system that uses compressed air to transmit and control
energy.
Pneumatic systems are used in controlling train doors, automatic production lines,
mechanical clamps,

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Figure 2 Pneumatic system of an automatic machine
3.2 The advantages of pneumatic systems
Pneumatic control systems are widely used in our society, especially in the industrial
sectors for the driving of automatic machines. Pneumatic systems have a lot of
advantages..
3.2.1 High effectiveness
Many factories have equipped their production lines with compressed air supplies and
movable compressors. There is an unlimited supply of air in our atmosphere to
produce compressed air.
Moreover, the use of compressed air is not restricted by distance, as it can easily be
transported through pipes.
3.2.2 High durability and reliability
Pneumatic components are extremely durable and can not be damaged easily.
Compared to electromotive components, pneumatic components are more durable and
reliable.
3.2.3 Simple design
The designs of pneumatic components are relatively simple. They are thus more
suitable for use in simple automatic control systems.

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3.2.4 High adaptability to harsh environment
Compared to the elements of other systems, compressed air is less affected by high
temperature, dust, corrosion, etc.
3.2.5 Safety
Pneumatic systems are safer than electromotive systems because they can work in
inflammable environment without causing fire or explosion. Apart from that,
overloading in pneumatic system will only lead to sliding or cessation of operation.
Unlike electromotive components, pneumatic components do not burn or get
overheated when overloaded.
3.2.6 Easy selection of speed and pressure
The speeds of rectilinear and oscillating movement of pneumatic systems are easy to
adjust and subject to few limitations. The pressure and the volume of air can easily be
adjusted by a pressure regulator.
3.2.7 Environmental friendly
The operation of pneumatic systems do not produce pollutants. The air released is also
processed in special ways. Therefore, pneumatic systems can work in environments
that demand high level of cleanliness. One example is the production lines of
integrated circuits.
3.2.8 Economical
As pneumatic components are not expensive, the costs of pneumatic systems are quite
low. Moreover, as pneumatic systems are very durable, the cost of repair is
significantly lower than that of other systems.
Pneumatic system are very because they use compressed air. If a pneumatic system
develops a leak it will be air that escapes and not oil. This air will not drip or cause a
mass production lines.
Pneumatic system are very safe compared to other systems. Electronics paint spraying
because many electronic components produce sparks and this could cause the paint to
catch fire.
Pneumatic system are very reliable and can keep working for a long time. Many
companies invest in pneumatic because they know they will not have a lot of
breakdowns and that equipment will last for a long time.
If we compare pneumatic systems to other systems, we find that they are cheaper to
run. This is because the components last for compressed air. the components last for
compressed air.
Once you have bought the basic components, you can set them up to carry out
different tasks. Pneumatic systems are easy to install and they do not need to be
insulated or protected like electronic systems.

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Different bore cylinders change the available force
By adjusting the applied pressure you can instantly adjust the force
No burned up motors – stall with no damage
• Easy to expand once installed Complete kit
• Weight
equal or lighter than comparable alternatives
• Simple
Review the manual that comes with the pneumatic kit and you’re ready to go
• Strong
Force from 9 lbs to 180 lbs – easily adjustable
3.3 Limitations of pneumatic systems
Although pneumatic systems possess a lot of advantages, they are also subject to
many limitations.
3.3.1 Relatively low accuracy
As pneumatic systems are powered by the force provided by compressed air, their
operation is subject to the volume of the compressed air. As the volume of air may
change when compressed or heated, the supply of air to the system may not be
accurate, causing a decrease in the overall accuracy of the system.Technological
Studies Pneumatic Systems.
3.3.2 Low loading
As the cylinders of pneumatic components are not very large, a pneumatic system
cannot drive loads that are too heavy.
3.3.3 Processing required before use
Compressed air must be processed before use to ensure the absence of water vapour
or dust.Otherwise, the moving parts of the pneumatic components may wear out
quickly due to friction.
3.3.4 Uneven moving speed
As air can easily be compressed, the moving speeds of the pistons are relatively
uneven.

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3.3.5 Noise
Noise will be produced when compressed air is released from the pneumatic
components.
3.4 Main pneumatic components
Pneumatic components can be divided into two categories:
1. Components that produce and transport compressed air.
2. Components that consume compressed air.
All main pneumatic components can be represented by simple pneumatic symbols.
Each symbol shows only the function of the component it represents, but not its
structure. Pneumatic symbols can be combined to form pneumatic diagrams. A
pneumatic diagram describes the relations between each pneumatic component, that
is, the design of the system.
3.4.1 Compressor
A compressor can compress air to the required pressures. It can convert the
mechanical energy from motors and engines into the potential energy in compressed
air. A single central compressor can supply various pneumatic components with
compressed air, which is transported through pipes from the cylinder to the pneumatic
components. Compressors can be divided intotwo classes: reciprocatory and rotary.
Figure 3 Compressor used in Laboratories
3.4.2Pressure regulating component
Pressure regulating components are formed by various components, each of which has
its own pneumatic symbol:

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(i) Filter – can remove impurities from compressed air before it is fed to the
pneumatic components.
(ii) Pressure regulator – to stabilise the pressure and regulate the operation of
pneumatic components
(iii) Lubricator – To provide lubrication for pneumatic components
Figure 4 Pressure regulating component
3.4.3 The consumption of compressed air
Examples of components that consume compressed air include execution components
(cylinders), directional control valves and assistant valves.
3.4.4 Execution component
Pneumatic execution components provide rectilinear or rotary movement. Examples
of pneumatic execution components include cylinder pistons, pneumatic motors, etc.
Rectilinear motion is produced by cylinder pistons, while pneumatic motors provide
continuous rotations.There are many kinds of cylinders, such as single acting
cylinders and double acting cylinders.
3.4.5 Single acting cylinder
A single acting cylinder has only one entrance that allows compressed air to flow
through.Therefore, it can only produce thrust in one direction. The piston rod is
propelled theopposite direction by an internal spring, or by the external force provided
by mechanical movement or weight of a load.

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Figure 5 Cross section of a single acting cylinder
Figure 6 Single acting cylinder
The thrust from the piston rod is greatly lowered because it has to overcome the force
from the spring. Therefore, in order to provide the driving force for machines, the
diameter of the cylinder should be increased. In order to match the length of the
spring, the length of the cylinder should also be increased, thus limiting the length of
the path. Single acting cylinders are used in stamping, printing, moving materials, etc.
3.5 Control valve
A control valve is a valve that controls the flow of air. Examples include non-return
valves, flow control valves, shuttle valves, etc.

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3.5.1 Non-return valve
A non-return valve allows air to flow in one direction only. When air flows in the
opposite direction, the valve will close. Another name for non-return valve is poppet
valve .
Figure 7 Non-return valve
3.5.2 Flow control valve
A flow control valve is formed by a non-return valve and a variable throttle
Figure 8 Flow control valve

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Figure 9 Cross section
3.5.3Shuttle valve
Shuttle valves are also known as double control or single control non-return valves. A
shuttle valve has two air inlets ‘P1’ and ‘P2’ and one air outlet ‘A’. When compressed
air enters through‘P1’, the sphere will seal and block the other inlet ‘P2’. Air can then
flow from ‘P1’ to ‘A’. When the contrary happens, the sphere will block inlet ‘P1’,
allowing air to flow from ‘P2’ to ‘A’ only.
Figure 10 (a) Shuttle valve Figure 11 (b) Cross section
Figure 12 (c) Connecting pipes

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3.6 Application
Internal flat surfaces.
i. Enlargement and finishing non-circular bounded by a number of flat
surfaces .
ii. Internal grooves and slots of rectangular and curved section.
iii. Internal key way and splines of rectangular ,straight tooth of internal spur
gear’s internal curved surface of circular section ,internal oil grooves
etc………
iv. Pneumatics are good for straight movements, but, with the right linkage
can be used for rotation or other movements.
3.7 Characteristic:
i. Vertical tool reciprocating with down stroke acting.
ii. Longer stroke length.
iii. Lees strong and rigid.
iv. An additional rotary feed motion of the work table.
v. Used mostly for machining internal surfaces.
3.8 DisadvantagesforPneumatics
• Initial weight cost is high ~15lbs
• Requires fine tuning for optimum use
• Limited uses with larger actuators

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4 COST ESTIMATION
4.1 INTRODUCTION:-
Cost estimation may be defined as the process of forecasting the expenses that must
be incurred to manufacture a product. These expenses take into a consideration all
expenditure involved in a design and manufacturing with all related services facilities
such as pattern making, tool, making as well as a portion of the general administrative
and selling costs.
4.2 PURPOSE OF COST ESTIMATING:
1. To determine the selling price of a product for a quotation or contract so
as to ensure a reasonable profit to the company.
2. Check the quotation supplied by vendors
.
3. Determine the most economical process or material to manufacture the
product.
4. To determine standards of production performance that may be used to
control the cost
4.3 TYPES OF COST ESTIMATION:-
1. Material cost
2. Machining cost
4.3.1 MATERIAL COST ESTIMATION:
Material cost estimation gives the total amount required to collect the raw material
which has to be processed or fabricated to desired size and functioning of the
components.These materials are divided into two categories
.
4.3.2 Material for fabrication:
In this the material in obtained in raw condition and is manufactured or processed to
finished size for proper functioning of the component.
4.3.3 Standard purchased parts:
This includes the parts which was readily available in the market like allen screws etc.
A list in forchard by the estimation stating the quality, size and standard parts, the
weigh of raw material and cost per kg. For the fabricated parts.

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4.4 MACHINING COST ESTIMATION:
This cost estimation is an attempt to forecast the total expenses that may include to
manufacture apart from material cost. Cost estimation of manufactured parts can be
considered as judgment on and after careful consideration which includes lab our,
material and factory services required to produce the required
SR.NO MACHINE TIME OF
HOURS
RATE IN
RS.
OPERATION RUPEES
(1) LATHE 5 100 TURNING&
BORING
500
(2) MILLINGM/C 4 150 TEETHSLOT
AND GEARS
600
(3) WELDINGM/C 4 100 FIXINGTHE
LINKAGES
400
(4) DRILLINGM/C &
TAPPINGDIE SET
4 100 MAKINGHOLES
& THREADS
400
(5) BORING
ATTACHIMENT
2 120 FINISHINDDIA 240
(6) GRINDINGM/C 2 100 FINISHINGTHE
COMP.
200
(7) CUTTINGM/C 3.5 100 PARTINGOFF
OBJECTS
350

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SR.NO MACHINE TIME OF
HOURS
RATE IN
RS.
OPERATION RUPEES
(1) LATHE 5 100 TURNING&
BORING
500
(2) MILLINGM/C 4 150 TEETHSLOT
AND GEARS
600
(3) WELDINGM/C 4 100 FIXINGTHE
LINKAGES
400
(4) DRILLINGM/C &
TAPPINGDIE SET
4 100 MAKINGHOLES
& THREADS
400
(5) BORING
ATTACHIMENT
2 120 FINISHINDDIA 240
(6) GRINDINGM/C 2 100 FINISHINGTHE
COMP.
200
(7) CUTTINGM/C 3.5 100 PARTINGOFF
OBJECTS
350
Table 2 cost esmating
5 Conclusionand Future Scope
5.1 Future Scope
Since old age man is always trying to gain more and more luxurious. Man is
always trying to develop more and more modified technique with increasing
the aesthetic look and economic consideration. Hence there is always more
and more scope. But being the degree Engineers and having the ability to think
and plan. But due to some time constraints, and also due to lack of funds, we
only have thought and put in the report the following future modifications:-
1) It can be made to run has bottle cap sealing machine. The stationary
platform can be made auto swiveling type by installing the timer and heat
sensor arrangement on the platform. It can be done such that when the bottle
mouth is sealed up to the desired temperature the electrical heater circuit gets
cut off . At the same time the motor installed on the reduction gear box starts

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operating the bevel gearing and the platform starts rotating thus it can be made
auto rotating type.
2) It can be made hydraulic operated type by replacing the hand lever by
hydraulic cylinder and along with the ratchet and Paul arrangement..
3) It can be made hydraulically power operated by installing the gear oil pump
at the place of air compressor and pneumatic cylinder arrangement.
4) It can be made rack and pinion operated or spring and lever operated, by
replacing the pneumatic circuit by rack and the pinion arrangement by the
square threaded screw and nut arrangement.
5) The place where there is scare city of the electricity the electric motor
operate compressor is replaced by an I.C.Engine installed compressor. Thus in
future there are so many modifications, which we can make to survive the
huge global world of competition.
5.2 Conclusion
Now we know that Pneumatic Shearing machine is very cheap as compared to
hydraulic shearing machine. The range of the cutting thickness can be
increased by arranging a high pressure compressor and this machine is
advantageous to small sheet metal cutting industries as they do not have rely
on the expensive hydraulic shearing machine.
6 Reference
i. Google search:
ii. Mechanical project.
iii. http://mechamachinery.blogspot.in/p/sloter.html?m=1.

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SAFETY PRECAUTIONS WHEN WORKINK WITH SHAPING
MACHINES
1. Wear Approved Goggles or face Shield.
2. Select Proper tool for the job.
3. Be sure that Tool Head, Table Support are Secure before Starting the
Machine.
4. Remove all Wrenches before Starting the Machine.
5. Select the Proper Speed, feed, and Depth of cut according to the kind of
Material, type of Tool,and Method of Holding the Work.
6. Stand Parallel to the Direction of the Stroke of the Machine When it is
Operating , and Never Reach across the Table between strockes.
7. Do not Touch the Tool, Clapper box, or w/p While the Machine is Running.
8. Make Adjustment on the Work Setup only When the Machine is Stopped.
9. Turn off the Machine before Leaving it.